ROTATING ELECTRIC MACHINE

Abstract

In order to provide a rotating electrical machine such that a size reduction can be achieved, and a balance between cooling performance and vibration resistance can be obtained, a plurality of connection portions (6) formed of a first connection portion (6a) and a second connection portion (6b) which mechanically connect a main body of a rotating electrical machine (200) and a power converter (300) is provided on a non-external device (2) connection portion side mount in the main body of a rotating electrical machine (200) and a heat dissipation element (11) in the power converter (300), the centers of the cross sections of the first connection portion (6a) and the second connection portion (6b) are made to be positioned further away from an inner diameter side than from an outer diameter side of a stator (3),and a power module (22) is disposed between two adjacent connection portions (6) in a circumferential direction. Fig. 3,

Description

Title of the invention: ROTATING ELECTRIC MACHINE Technical field

[0001] The present application relates to a rotating electrical machine. Prior art

[0002] A rotating electric machine mounted in a motor vehicle or the like comprises a rotating electric machine main body and a power converter comprising an inverter that controls the rotating electric machine main body, and for reasons such as space conservation, ease of mounting, and reduction in the size of a wiring harness that connects the rotating electric machine main body and the inverter, an electromechanical integrated rotating electric machine in which the rotating electric machine main body and the inverter are integrated is being developed.

[0003] Furthermore, a rotating electrical machine comprising a power converter that includes an inverter or a rectifier circuit comprises a cooling structure that cools the power converter and a structure that attaches and fixes the power converter to the rotating electrical machine main body (for example, see Patent Document 1, Patent Document 2 and Patent Document 3).

[0004] Patent Document 1: Japanese Patent No. 5,729,268 Patent Document 2: Japanese Patent No. 4,392,352 Patent Document 3: Japanese Patent No. 5,602,214 Technical problem

[0005] However, a rotating electric machine disclosed in Patent Document 1 is such that a protruding portion provided on a rear frame is disposed on one side of the inner diameter of a stator, and the rear frame and a power module are directly joined, which means that when the rotating electric machine is used as a motor, heat generated by the stator is conducted to the power module, and it is feared that this will cause the temperature of the power module to worsen. In addition, a rotating electric machine disclosed in Patent Document 2 is such that a plurality of fixing studs which fix and support a power converter are arranged scattered on an inner diameter side of a stator, due to which a radial direction cooling passage is blocked, and the cooling performance of a power module is not necessarily optimal.

[0006] Furthermore, a rotating electric machine disclosed in Patent Document 3 is such that a bracket included in a rear mount so that the rotating electric machine and an inverter can be easily disassembled is provided on an outer diameter side of a stator core, due to which the rotating electric machine increases in size on the outer diameter side, thereby decreasing the ease of mounting in a vehicle. In addition, a connection portion is provided in a radial direction passage between the rear mount and a heat sink, which means that when a contact area of ​​a cross-section of the connection portion is large, the radial direction passage between the rear mount and the heat sink becomes smaller, and the cooling performance of the power module deteriorates. Conversely, when the contact area in cross-section of the connection portion is small, the cooling performance of the power module improves, but the vibration resistance decreases, and there is a concern that disconnection occurs in a semiconductor element of the power module for which a bonding wire such as an aluminum wire bond is used. Technical solution

[0007] A rotating electric machine disclosed in the present application is a rotating electric machine comprising a rotating electric machine main body, a power converter which is provided on one end of a rotating shaft of the rotating electric machine main body and exchanges electricity with the rotating electric machine main body via a current collector, and an external device connection portion which is attached to another end of the rotating shaft of the rotating electric machine main body, wherein the rotating electric machine main body comprises an external device connection portion-side mount and a non-external device connection portion-side mount configuring a housing, a rotor,which is supported so as to be capable of rotation by the external device connection portion-side mount and the non-external device connection portion-side mount and is disposed inside the housing, a fan, which is mounted on the rotor and blows air in accompaniment to rotation, and a stator, which is held on each side in the axial direction by the external device connection portion-side mount and the non-external device connection portion-side mount and is disposed so as to surround the rotor, the power converter comprises a power circuit unit having a plurality of power modules which include one or more sets of power semiconductor elements, a control unit which controls the power circuit unit, and a heat dissipation member which cools the power circuit unit, power module, a plurality of connection portions formed of a first connection portion and a second connection portion which mechanically connect the rotating electric machine main body and the power converter are provided on the non-external device connection portion-side mount and the heat dissipation member, cross-sectional centers of the first connection portion and the second connection portion are caused to be positioned farther toward an inner diameter side than an outer diameter of the stator, and the power module is disposed between the two neighboring connection portions in a circumferential direction. Benefits provided

[0008] According to the rotating electrical machine disclosed in the present application, a size reduction can be achieved, and a balance between the cooling performance of the power module and the vibration resistance in a power converter can be achieved. The foregoing and other objects, features, aspects and advantages of the present application will become more apparent from the following detailed description of the present application when taken in conjunction with the accompanying drawings. Brief description of the drawings

[0009] Other characteristics, details and advantages of the invention will appear on reading the detailed description below, and on analyzing the appended drawings, in which: Fig.l

[0010] [Fig.l] is a perspective view showing an external appearance of a rotating electrical machine according to a first embodiment; Fig. 2

[0011] [Fig.2] is a schematic view showing a cross-section along a shaft rotary of the rotating electric machine of [Fig.l]; Fig. 3

[0012] [Fig.3] is a schematic view of the rotating electrical machine according to the first embodiment viewed from a side without pulley of a cross-section perpendicular to the rotating shaft; Fig. 4

[0013] [Fig.4] is a sectional view showing a configuration of a main portion of the rotating electrical machine according to the first embodiment; Fig. 5

[0014] [Fig.5] is a schematic view of a rotating electrical machine according to a second embodiment viewed from a side without pulley of a cross-section perpendicular to a rotating shaft; Fig. 6

[0015] [Fig.6] is a schematic view showing a cross-section along a shaft rotary of a rotating electrical machine according to a third embodiment; Fig. 7

[0016] [Fig.7] is a schematic view of the rotating electrical machine according to the third embodiment viewed from a side without pulley of a cross-section perpendicular to the rotating shaft; Fig. 8

[0017] [Fig.8] is a schematic view of a rotating electrical machine according to a fourth embodiment viewed from a side without pulley of a cross-section perpendicular to a rotating shaft; Fig. 9A to 9E

[0018] [Fig. 9A to 9E] are sectional views showing enlargements of principal portions of the rotating electrical machines of [Fig. 2] and 7; and; Fig. 10

[0019] [Fig. 10] is a schematic view showing a modification of a machine rotating electric. Description of the embodiments

[0020] Hereinafter, embodiments of the present application are described, based on the drawings. Identical or corresponding portions in the drawings are described by assigning them like reference signs.

[0021] First embodiment [Fig.l] is a perspective view showing an external appearance of a rotating electrical machine according to a first embodiment. In the drawing, a rotating electric machine 100 is configured of a rotating electric machine main body 200, a power converter 300, which is disposed at one end of a rotating shaft of the rotating electric machine main body 200 and exchanges electricity with the rotating electric machine main body 200, and an external device connection portion 400 attached to another end of the rotating shaft.

[0022] Here, an exterior of the rotating electric machine main body 200 is formed of an external device connection portion-side mount 1 and a non-external device connection portion-side mount 2, which configure a housing, and a stator 3 which is fixed to and supported by the external device connection portion-side mount 1 and the non-external device connection portion-side mount 2, and the rotating electric machine main body 200 operates as a motor which drives or assists a gear device (not shown) or an internal combustion engine connected to the external device connection portion 400, and further functions as a generator driven by the gear device or the internal combustion engine. In addition, the power converter 300 functions as an inverter circuit for controlling the rotating electric machine main body 200 or as a converter circuit that converts the power generated by the rotating electric machine main body 200. Although a pulley is shown as the external device connection portion 400, various structures that can be connected to an external device may be employed.

[0023] [Fig. 2] is a schematic view showing a cross-section along the rotating shaft of the rotating electrical machine of [Fig. 1]. In the drawing, the rotating electric machine main body 200 comprises the stator 3, which is installed on and supported by the external device connection portion-side mount 1 and the non-external device connection portion-side mount 2, a rotating shaft 4, which is supported so as to be capable of rotation by the external device connection portion-side mount 1 and the non-external device connection portion-side mount 2 via the bearings 9 and 10, a rotor 5, which is attached to the rotating shaft 4 and disposed opposite the stator 3, and a current collector 16, which electrically connects the rotor 5 and the power converter 300. Here, the stator 3 has a circular outer shape and comprises a stator core 3a and a stator winding 3b which protrudes from both end portions of the stator core 3a and is mounted on the stator core 3a. In addition, the current collector 16 is configured with a slip ring 16a attached to the rotating shaft 4, a brush 16b which conducts current by coming into contact with the slip ring 16a and a brush holder 16c which holds the brush 16b.

[0024] Simultaneously, the rotor 5 comprises a rotor core 5a supported by the rotating shaft 4, a field winding 5b wound around the rotor core 5a, and fans 7 and 8 which are each attached at one end in a direction of the rotation axis of the rotor core 5a, and cause generation of a refrigerant flow by being driven by the rotating shaft 4. The fans 7 and 8 have main plates 7a and 8a, which are attached to the rotor core 5a, and blades 7b and 8b, the blades 7b and 8b being rotated in accompaniment to a rotation of the rotating shaft 4, leading to the generation of a refrigerant flow.

[0025] In the external device connection portion side mount 1, an external device connection portion side refrigerant inlet portion 1a is formed. in an external device connection portion-side end face and an external device connection portion-side channel outlet portion 1b is formed in an end face in the radial direction, and these are configured so as to cause a refrigerant to flow into an interior of the external device connection portion-side mount 1 and cause the refrigerant to flow from the interior of the external device connection portion-side mount 1, with rotation of the external device connection portion-side fan 7 as a power supply. Furthermore, in the non-external device connection portion-side mount 2, a non-external device connection portion-side mount refrigerant inlet portion 2a is formed in an external device connection portion-side end face and a non-external device connection portion-side mount refrigerant outlet portion 2b is formed in an end face in the radial direction, and these are configured so as to cause a refrigerant to flow into an interior of the non-external device connection portion-side mount 2 and cause the refrigerant to flow from the interior of the non-external device connection portion-side mount 2, with rotation of the non-external device connection portion-side fan 8 as a power supply.

[0026] Below, a configuration of the power converter 300 is described. The power converter 300 is attached to a non-external device connection portion side in the rotation axis direction of the non-external device connection portion side mount 2 via a connection portion 6, and has a cover 15 that encircles an entirety of the power converter 300, a power circuit unit 21, a control unit 13 that controls the power circuit unit 21, and a heat dissipation member 11 that is thermally bonded to cool the power circuit unit 21. The connection portion 6 is configured of a first connection portion 6a, which is provided protruding from the non-external device connection portion 2-side mount, and a second connection portion 6b, which is provided protruding on the heat dissipation member 11 and is in contact with the first connection portion 6a. In addition, the control unit 13 includes a substrate 13a and an electronic part 13b which is attached to the substrate 13a and electrically connected.

[0027] Furthermore, a plurality of fins 12 are formed on the heat dissipation member 11 for the purpose of increasing a cooling capacity. Furthermore, a housing 14 which surrounds an outer periphery of the control unit 13 and the power circuit unit 21 is provided, and an input / output terminal 18 (see [Fig. 3]) which connects a power module 22 to an external circuit is provided on an exterior of the housing 14. Further, still, a power semiconductor element of the power circuit unit 21 is disposed further toward an outer side in a radial direction. than a portion at the innermost diameter of the blade 8b of the fan 8, whereby a good cooling action can be obtained.

[0028] [Fig.3] is a schematic view showing an internal arrangement of the power converter 300 of [Fig.2] in cross-section in a direction perpendicular to the rotating shaft. In the drawing, the power circuit unit 21 comprises the power module 22, which comprises one or more sets of power semiconductor elements 23 configuring upper and lower arms, and the power semiconductor element 23 is connected to a wiring member 24 through a junction member 25, as shown in [Fig. 4], and configured integrated by molding using a resin material 26. In addition, the connection portion 6 is provided in such a manner that a cross-sectional center C1 thereof is positioned further toward an inner side than an outer diameter D1 of the stator 3, and a plurality of power modules 22 are disposed between two neighboring connection portions 6 in a circumferential direction. Furthermore, the power modules 22 are disposed in the circumferential direction with the rotating shaft 4 as a center, and at least one connection portion 6 is disposed between two power modules 22 in view along the circumferential direction.

[0029] With the connection portion 6 installed in this way inside the passage of a refrigerant flowing in the radial direction between the non-external device connection portion-side mount 2 and the heat dissipation member 11, the refrigerant flows branching off to each power module 22, and the power module 22 can be cooled efficiently. In this case, a cross-sectional area A1 of the connection portion 6 is desirably smaller than a bottom face area A2 of a power module installed between the connection portions 6.

[0030] Furthermore, a power converter refrigerant inlet portion 19 is formed in an outer peripheral face in the radial direction of the power converter 300, and a power converter refrigerant outlet portion 20 is formed in an external device connection portion-side end face in the rotation axis direction of the power converter 300, and these are configured so as to cause a refrigerant to flow into the power converter 300 and cause the refrigerant to flow out of the power converter 300, with rotation of the fan 8 as a power supply.

[0031] Since the power converter 300 is provided on the non-external device connection portion side, in the rotation axis direction, of the rotating electric machine main body 200, a refrigerant that has flowed out of the refrigerant outlet portion of the power converter 20 flows into the main body. of rotating electric machine 200 via the refrigerant inlet portion of the non-external device connection portion side mount 2a, which is also the refrigerant outlet portion of the power converter 20.

[0032] The rotating electrical machine 100 configured as described above is such that the connection portion 6 is arranged in such a manner that a refrigerant is caused to branch off to each power module 22, thereby improving cooling performance, and further, the power module 22 is not mounted on the connection portion 6, thereby achieving improved cooling performance. In addition, the connection portion 6 has a configuration in which its cross-sectional area A1 is smaller than the bottom face area A2 of the power module 22, whereby a cooling passage under the power module 22 can be ensured, and cooling performance can be improved.Also, since the connection portion 6 is arranged further toward the inner diameter side than the outer diameter DI of the stator core 3a, size reduction and safety improvement can be achieved. In particular, a balance between improved cooling performance of the power module 22 and vibration resistance can be achieved by arranging at least three connection portions 6 in a dispersed manner.

[0033] Second embodiment [Fig.5] is a schematic view showing an internal arrangement of a power converter of a rotating electrical machine according to a second embodiment in cross-section in a direction perpendicular to a rotating shaft. In the drawing, the power converter 300 is configured such that the power module 22 is arranged on a line L1 connecting the centers of the cross sections C1 of two neighboring connection portions 6 in the circumferential direction. Since the other configurations are the same as in the first embodiment, the same reference signs are assigned, and a description thereof is omitted.

[0034] The rotating electric machine 100 configured in this manner is configured in such a way that, even if the power module 22 is disposed farther toward an outer peripheral side, the connection portion 6 is not disposed farther toward the outer side than the outer diameter DI of the stator 3, whereby a large region can be centrally provided in the power converter 300, with a maintained size reduction. Therefore, for example, electrical wiring that electrically connects the power module 22 and the input / output terminal 18, or a fixing member of the electrical wiring, and furthermore, other electronic parts such that an inductor and a capacitor configuring a filter circuit, can be mounted in the region.

[0035] Third embodiment [Fig.6] is a sectional view in the axial direction of a rotating electrical machine according to a third embodiment, and [Fig.7] is a schematic view showing an internal arrangement of the power converter 300 of [Fig.6] in cross-section in a direction perpendicular to a rotating shaft. In the third embodiment, a space is formed by providing a hole in a central portion of the heat dissipation member 11, and the current collector 16 is disposed in the space portion. Furthermore, the housing 14, which separates the control unit 13 and the current collector 16, is provided so that wear debris from the brush 16b does not encroach on the side of the control unit 13. When other configurations are the same as in the second embodiment, the description thereof will be omitted.

[0036] The rotating electrical machine 100 configured in this manner is such that even if a reduction in size in the radial direction is maintained, the size can also be reduced in the axial direction.

[0037] Fourth embodiment [Fig.8] is a schematic view showing an internal arrangement of a power converter of a rotating electrical machine according to a fourth embodiment in cross-section in a direction perpendicular to a rotating shaft. In the fourth embodiment, two power modules 22 are arranged between the neighboring connection portions 6 in the circumferential direction. Since the other configurations are the same as in the first or second embodiment, the same reference signs are assigned to identical portions, and a description thereof is omitted.

[0038] The rotating electrical machine 100 thus configured is such that a heat density generated by the power module 22 can be dispersed by a plurality of power modules 22 arranged between the connection portions 6, whereby a temperature rise of the power module 22 can be restricted. In addition, the freedom of arrangement can be increased by reducing the size of the power module.

[0039] Above, embodiments of the present application have been described, but these show examples, and the present application is such that a rotating electrical machine can be configured by combining characteristic configurations of the embodiments where appropriate, and various shapes can be employed, as described below. That is, although a cross-sectional shape of the connecting portion 6 is shown as circular in the embodiments described above, various shapes, such as a rectangular shape, a polygonal shape, or an elliptical shape, may be employed. Also, although a housing in which four connecting portions 6 are installed at equal intervals on the same radius is shown in the drawings, the arrangement need not be limited to a same radius, the number need not be limited to four, and may be any number equal to two or more, and the installation intervals need not be equal intervals.

[0040] Furthermore, although the connection portion 6 shown in [Fig. 2] and 7 is such that each of the first connection portion 6a of the non-external device connection portion-side mount 2 and the second connection portion 6b of the heat dissipation member 11 is configured to be protruded, a configuration may be such that only the first connection portion 6a of the non-external device connection portion-side mount 2 is protruded while the second connection portion 6b of the heat dissipation member 11 is flat-shaped, as shown in [Fig. 9A], or such that only the second connection portion 6b is caused to be protruded, as shown in [Fig. 9B]. In addition, the second connection portion 6b may be formed by providing a recessed portion in the heat dissipation member 11, and the first connection portion 6a inserted into the recessed portion, as illustrated in [Fig.9C], or the first connection portion 6a may be formed by providing a recessed portion in the non-external device connection portion-side mount 2, and the second connection portion 6b inserted into the recessed portion, as illustrated in [Fig.9D]. Furthermore, an intermediate member 31 made of resin or the like, whose thermal conductivity is lower or whose insulation is better than that of the non-external device connection portion-side mount 2 and the heat dissipation member 11, may be provided between the first connection portion 6a and the second connection portion 6b, as illustrated in [Fig.9E].

[0041] Furthermore, a power semiconductor element consisting of six sets of upper and lower arms to configure two sets of three-phase full-wave rectifiers may be included as a power circuit unit 21, in which case various configurations may be employed by, for example, four power semiconductor elements consisting of two sets of upper and lower arms, or six power semiconductor elements consisting of three sets of upper and lower arms, included in the power module 22. Similarly, power converters having different numbers of phases, such as a five-phase power converter having five power modules 22 consisting of one set of upper and lower arms, a power converter six-phase having six power modules 22, or a seven-phase power converter having seven power modules 22, may be used. Further, the power modules 22 may be arranged intermixed so as to include, for example, one or more each of a power module consisting of an upper and lower arm assembly and a power module consisting of two upper and lower arm assemblies.

[0042] Furthermore, an electric circuit 32 that controls an amount of current flowing to the field winding 5b included in the rotating electric machine main body 200 may be disposed in the heat dissipating member 11, and the electric circuit may be an electric circuit module whose external appearance is that of a module sealed with a sealing agent such as the resinous material 26, in the same manner as the power module 22. Also including this type of case, three power modules 22 and one electric circuit 32 may be disposed, as shown in [Fig. 10], and may be aligned in any order. Also, a form in which there are four power modules 22 rather than the electric circuit 32 may be used. List of cited documents Patent documents

[0043] For all useful purposes, the following patent document is cited: - [Patent Document 1] Japanese Patent No. 5,729,268 - [Patent Document 2] Japanese Patent No. 4,392,352 - [Patent Document 3] Japanese Patent No. 5,602,214.

Claims

Claims

1. Rotating electrical machine (100), comprising: a rotating electric machine main body (200); a power converter (300) which is provided at one end of a rotating shaft (4) of the rotating electric machine main body (200) and exchanges electricity with the rotating electric machine main body (200) via a current collector (16); and an external device connection portion (400) which is attached to another end of the rotating shaft (4) of the rotating electric machine main body (200), wherein the rotating electric machine main body (200) comprises an external device connection portion-side mount (1) and a non-external device connection portion-side mount (2) configuring a housing, a rotor (5), which is supported so as to be capable of rotation by the external device connection portion-side mount (1) and the non-external device connection portion-side mount (2) and is disposed inside the housing, a fan (8), which is mounted on the rotor (5) and blows air in accompaniment to rotation, and a stator (3), which is held on each side in the axial direction by the external device connection portion-side mount (1) and the non-external device connection portion-side mount (2) and is disposed so as to encircle the rotor (5),the power converter (300) comprises a power circuit unit (21) having a plurality of power modules (22) which include one or more sets of power semiconductor elements (23), a control unit (13) which controls the power circuit unit (21), and a heat dissipation member (11) which cools the power circuit unit (21), a plurality of connection portions (6) formed of a first connection portion (6a) and a second connection portion (6b) which mechanically connect the rotating electric machine main body (200) and the power converter (300) is provided on the non-external device connection portion-side mount (2) and the heat dissipation member (11),centers of the cross sections of the first connection portion (6a) and the second connection portion (6b) are caused to be positioned further toward an inner diameter side than an outer diameter of the stator (3), and the, power module (22) is arranged between two connection portions (6) adjacent in a circumferential direction.

2. A rotating electrical machine according to claim 1, wherein the power module (22) is arranged on a line connecting the centers of the cross sections of the two connection portions (6).

3. A rotating electric machine according to claim 1 or 2, wherein the connection portion (6) is provided in a radial direction passage between the non-external device connection portion-side mount (2) and the heat dissipation member (11), and is configured such that a refrigerant branches to each power module (22) through the connection portion (6), and a cross-sectional area of the connection portion (6) is smaller than a bottom face area of the power module (22) installed between the connection portions (6).

4. A rotating electrical machine according to any one of claims 1 to 3, wherein the power circuit unit (21) comprises the power semiconductor element (23) having six sets of upper and lower arms which configure two sets of full-wave three-phase rectifiers.

5. A rotating electric machine according to any one of claims 1 to 4, wherein the power semiconductor element (23) is configured by being molded using a resin member, and the resin molded member (26) is disposed within an outer diameter of the stator (3).

6. A rotating electric machine according to any one of claims 1 to 5, wherein the power circuit unit (21) is disposed further toward a non-external device connection portion side than the current collector (16).

7. A rotating electric machine according to any one of claims 1 to 6, wherein the power semiconductor element (23) is disposed further toward an outer side in a radial direction than a portion at the innermost diameter of the blade (8b) of the fan (8).

8. A rotating electrical machine according to any one of claims 1 to 7, wherein a member (31) whose thermal conductivity is lower than that of the non-external device connection portion-side mount (2) and the heat dissipation member (11) is included between the first connection portion (6a) of the non-external device connection portion-side mount (2) and the second connection portion (6b). connection (6b) of the heat dissipation member (11).

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